Double flap valve with quick-change replaceable wear surface

Abstract

A flap-gate valve having a replaceable wear surface, methods of replacing a wear surface with a replacement wear surface, and methods of retrofitting an existing flap-gate valve with components adapted to work in conjunction with a replaceable wear surface.

The invention claimed is: 
     
       1. A method of replacing at least one component of a conventional flap-gate valve with at least one component adapted to work in conjunction with a replaceable face, the replaceable face comprising:
 a flat plate having at least one slot or bore therethrough, the at least one slot or bore having at least one bolt therethrough, for attaching the face to the bottom panel of a seat; 
 a face frame with a wear surface bordering said frame, the frame and the wear surface surrounding an opening in the flat plate, the wear surface comprising air-tight sealing material or abrasion-resistant material; 
 
       the method comprising the steps of:
 disengaging any screws or bolts from an existing seat in the flap-gate valve; 
 removing the existing seat from the conventional flap-gate valve; 
 installing a replacement seat comprising four side panels joined together, forming a substantially rectangular wall having an upper edge and a lower edge, and a bottom panel attached to the lower edge of the wall, the bottom panel comprising:
 a frame forming an opening; and 
 at least one bore adapted to accommodate a bolt; 
 
 bolting said face to the bottom panel of said replacement seat; 
 disconnecting and removing an existing arm and flapper from a shaft in the flap-gate valve; and 
 attaching to the shaft in the flap-gate valve a replacement arm and flapper, the arm being adapted to move the flapper into and out of sealing engagement with the wear surface on the replacement face. 
 
     
     
       2. A method for replacing a wear surface in a flap-gate valve, the flap-gate valve comprising:
 a seat comprising four side panels joined together, forming a substantially rectangular wall having an upper edge and a lower edge, and a bottom panel attached to the lower edge of the wall,
 the bottom panel comprising:
 a frame forming an opening; and 
 at least one bore adapted to accommodate a bolt; 
 
 wherein the surface of said seat does not comprise air-tight sealing material or abrasion-resistant material; 
 
 a replaceable face comprising:
 a first flat plate having at least one slot or bore therethrough, the at least one slot or bore having at least one bolt therethrough, the at least one bolt attaching the replaceable face to the bottom panel of the seat; 
 
 a piston-controlled arm; and 
 a flapper movably connected to said piston-controlled arm, said flapper comprising a flapper plate, 
 
       the steps of the method comprising:
 (a) removing the replaceable face from the bottom panel of the valve seat; and 
 (b) attaching a replacement replaceable face to the bottom panel of the seat, the replacement replaceable face comprising:
 a second flat plate having at least one slot or bore therethrough, the at least one slot or bore being adapted to attach the replacement replaceable face to the bottom panel of the seat; and 
 a face frame with a wear surface bordering said frame, the frame and the wear surface surrounding an opening in the second flat plate, the wear surface comprising air-tight sealing material or abrasion-resistant material, the wear surface being adapted to form a sealing engagement with the flapper when the flapper is moved into contact with the wear surface by the piston-controlled arm. 
 
 
     
     
       3. The method of  claim 2  for replacing a wear surface in a flap-gate valve, wherein:
 step (a) further comprises:
 loosening the at least one bolt attaching the replaceable face to the bottom panel of the seat; and 
 sliding the replaceable face out of engagement with the bottom panel of the seat; and 
 
 step (b) further comprises:
 sliding a replacement replaceable face having a replacement wear surface into engagement with the bottom panel of the seat; and 
 tightening the at least one bolt, thereby attaching the replacement replaceable face to the bottom panel of the seat. 
 
 
     
     
       4. The method of  claim 2  for replacing a wear surface in a flap-gate valve, wherein:
 step (a) further comprises:
 removing the at least one bolt attaching the replaceable face to the bottom panel of the seat; and 
 moving the replaceable face out of engagement with the bottom panel of the seat; and 
 
 step (b) further comprises:
 moving a replacement replaceable face having a replacement wear surface into engagement with the bottom panel of the seat; and 
 inserting and tightening the at least one bolt, thereby attaching the replacement replaceable face to the bottom panel of the seat. 
 
 
     
     
       5. A flap-gate valve with a replaceable wear surface, the flap-gate valve comprising:
 a seat comprising four side panels joined together, the side panels forming a substantially rectangular wall having an upper edge and a lower edge, and a bottom panel attached to the lower edge of the wall, the bottom panel comprising:
 a panel frame forming an opening; and 
 at least one bore adapted to accommodate a bolt; 
 
 wherein the surface of said seat does not comprise air-tight sealing material or abrasion-resistant material; 
 a replaceable face comprising:
 a flat plate having at least one slot or bore therethrough, the at least one slot or bore having at least one bolt therethrough, the at least one bolt attaching the face to the bottom panel of the seat; 
 a face frame with a wear surface bordering said face frame, the face frame and the wear surface surrounding an opening in the flat plate, the wear surface comprising air-tight sealing material or abrasion-resistant material; 
 
 a piston-controlled arm; and 
 a flapper movably connected to said piston-controlled arm to engage or disengage from said wear surface on said replaceable face, said flapper comprising a flapper plate which is shaped to form a sealing engagement with the wear surface of the face when engaged with said wear surface by said piston-controlled arm. 
 
     
     
       6. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the wear surface comprises rubber. 
     
     
       7. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the wear surface comprises a material selected from the group consisting of ceramic, tungsten carbide, and a combination of ceramic and tungsten carbide. 
     
     
       8. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the flat plate of the replaceable face comprises at least two indented sections forming slots, each slot being adapted to allow a bolt to pass through the flat plate, whereby the face is attached to the bottom panel of the seat. 
     
     
       9. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the flapper plate is circular in shape. 
     
     
       10. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the cross-sectional area of the rectangular wall in the seat tapers down in size from the upper edge of the wall to the lower edge of the wall. 
     
     
       11. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the bottom panel comprises at least two bores, each adapted to accommodate a bolt for attaching the face to the bottom panel of the seat. 
     
     
       12. The flap-gate valve with a replaceable wear surface of  claim 5 , wherein the bottom panel further comprises:
 two more bores, each having a bolt therethrough; and 
 on each said bolt, a metal tab adapted to hold a portion of the face against the bottom panel. 
 
     
     
       13. A kit for retrofitting a flap-gate valve, the kit comprising:
 a seat comprising:
 four side panels joined together, forming a substantially rectangular wall having an upper edge and a lower edge, and 
 a bottom panel attached to the lower edge of the wall, the bottom panel comprising:
 a bottom panel frame forming an opening, and 
 at least one bore adapted to accommodate a bolt; 
 
 wherein the surface of said seat does not comprise air-tight sealing material or abrasion-resistant material; 
 
 a replaceable face comprising:
 a flat plate having at least one slot or bore therethrough, the at least one slot or bore having at least one bolt therethrough, the at least one bolt attaching the face to the bottom panel of the seat; and 
 a face frame with a wear surface bordering the frame, the face frame and the wear surface surrounding an opening in the flat plate, the wear surface comprising air-tight sealing material or abrasion-resistant material; 
 
 a piston-controlled arm; and 
 a flapper movably connected to the piston-controlled arm to engage or disengage from the wear surface on the replaceable face, the flapper comprising a flapper plate shaped to form a sealing engagement with the wear surface of the frame face when engaged with the wear surface by the piston-controlled arm, 
 
       wherein a user removes an existing arm, an existing flapper, and an existing seat from a flap-gate valve and installs the seat, the face, the arm, and the flapper. 
     
     
       14. The kit of  claim 13 , wherein the wear surface comprises material selected from the group consisting of rubber, ceramic, tungsten carbide, and a combination of ceramic and tungsten carbide. 
     
     
       15. The kit of  claim 13 , wherein the flat plate of the replaceable face comprises at least two indented sections forming slots, each slot being adapted to allow a bolt to pass through the flat plate, whereby the replaceable face is attached to the bottom panel of the seat. 
     
     
       16. The kit of  claim 13 , wherein the flapper plate is circular in shape. 
     
     
       17. The kit of  claim 13 , wherein the cross-sectional area of the rectangular wall in the seat tapers down in size from the upper edge of the wall to the lower edge of the wall. 
     
     
       18. The kit of  claim 13 , wherein the bottom panel comprises at least two bores, each adapted to accommodate a bolt for attaching the replaceable face to the bottom panel of the seat. 
     
     
       19. The kit of  claim 13 , wherein the bottom panel of the seat further comprises:
 two more bores, each having a bolt therethrough; and 
 on each said bolt, a metal tab adapted to hold a portion of the face against the bottom panel.